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Toro Z580-D Operator'S Manual Download Page 6

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Page 1: ... Z580 D Z Master with a 52 Rear Discharge Mower Model No 74279TE Serial No 290000001 and Up To register your product or download an Operator s Manual or Parts Catalog at no charge go to www Toro com Original Instructions EN ...

Page 2: ...manual uses 2 other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention Contents Introduction 2 Safety 3 Safe Operating Practices 3 Toro Riding Mower Safety 5 Sound Pressure 5 Sound Power 5 Vibration 5 Slope Chart 6 Safety and Instructional Decals 7 Product Overview 14 Controls 14 Operation 1...

Page 3: ...perator or owner can result in injury To reduce the potential for injury comply with these safety instructions and always pay attention to the safety alert symbol which means CAUTION WARNING or DANGER personal safety instruction Failure to comply with the instruction may result in personal injury or death Safe Operating Practices The following instructions are from the CEN standard EN 836 1997 Thi...

Page 4: ... for humps and hollows and other hidden hazards Use care when pulling loads or using heavy equipment Use only approved drawbar hitch points Limit loads to those you can safely control Do not turn sharply Use care when reversing Watch out for traffic when crossing or near roadways Stop the blades rotating before crossing surfaces other than grass When using any attachments never direct discharge of...

Page 5: ...han 15 degrees Do not mow near drop offs ditches steep banks or water Wheels dropping over edges can cause rollovers which may result in serious injury death or drowning Do not mow slopes when grass is wet Slippery conditions reduce traction and could cause sliding and loss of control Do not make sudden turns or rapid speed changes Use a walk behind mower and or a hand trimmer near drop offs ditch...

Page 6: ...Slope Chart 6 ...

Page 7: ... 2 Thrown object hazard mower keep the deflector in place 3 Cutting dismemberment of hand or foot stay away from moving parts 93 7818 1 Warning read the Operator s Manual for instructions on torquing the blade bolt nut to 115 149 N m 85 110 ft lb 93 8069 1 Hot surface burn hazard stay a safe distance from the hot surface 98 1977 1 Entanglement hazard belt stay away from moving parts 98 4387 1 Warn...

Page 8: ...eat belt if the roll bar is lowered do not wear the seat belt 107 2114 107 2131 1 Hydraulic oil level 2 Warning do not touch the hot surface 107 3069 1 Warning there is no rollover protection when the roll bar is down 2 To avoid injury or death from a rollover accident keep the roll bar in the raised and locked position and wear the seat belt Lower the roll bar only when absolutely necessary do no...

Page 9: ...nual 2 Crushing hazard mower engage the parking brake stop the engine and remove the ignition key before working under the mower 107 7719 1 Cutting dismemberment hazard fan and entanglement hazard belt stay away from moving parts 2 Before starting the engine clean grass and debris from the mower belt and pulleys insert the ignition key and start the engine 108 5955 9 ...

Page 10: ...ngine is overheating 110 3853 1 Cutting dismemberment hazard fan and entanglement hazard belt 2 Remove the ignition key and read the instructions before servicing or performing maintenance 110 0305 112 3858 1 Read the Operator s Manual 3 Remove the ignition key before adjusting the height of cut 2 Read the instructions before servicing or performing maintenance 4 Height of cut settings 10 ...

Page 11: ...y 2 Read the instructions before servicing or performing maintenance 114 9600 1 Read the Operator s Manual 117 0912 1 Push to engage 4 Fast 2 Engine preheat 5 Continuous variable setting 3 Rear the Operator s Manual 6 Slow 117 3865 Manufacturer s Mark 1 Indicates the blade is identified as a part from the original machine manufacturer 11 ...

Page 12: ...use blindness and other injuries 3 Caustic liquid chemical burn hazard 8 Battery acid can cause blindness or severe burns 4 Wear eye protection 9 Flush eyes immediately with water and get medical help fast 5 Read the Operator s Manual 10 Contains lead do not discard 107 9309 1 Warning read the Operator s Manual for information on charging the battery contains lead do not discard 2 Read the Operato...

Page 13: ...ct hazard keep bystanders a safe distance from the machine and keep the deflector in place 4 Before starting the engine clean grass and debris from the mower belt and pulleys insert the ignition key and start the engine 107 3964 1 Warning do not use drugs or alcohol 3 Warning engage the parking brake stop the engine and remove the ignition key before leaving the machine 5 Read the Operator s Manua...

Page 14: ...before you start the engine and operate the machine Figure 3 and Figure 4 Figure 4 1 Hour meter 6 Glow plug light 2 Ignition switch 7 Engine Temperature light 3 Fuel selector valve 8 Throttle control 4 Audible alarm 9 PTO Switch 5 Glow plug switch Hour Meter The hour meter records the number of hours the engine has operated It operates when the engine is running Use these times for scheduling regu...

Page 15: ...g indicator light turns on when the glow plug button is engaged Figure 4 Glow Plug Switch This switch activates the glow plugs and is indicated by the glow plug light Hold down the glow plug switch for 10 seconds prior to starting Temperature Light The temperature light comes on when the engine is over heating Figure 4 Audible Alarm This machine has an audible alarm that alerts the user to turn of...

Page 16: ...rty Fill the fuel tank outdoors in an open area when the engine is cold Wipe up any fuel that spills Never fill the fuel tank inside an enclosed trailer Do not fill the fuel tank completely full Add fuel to the fuel tank until the level is 1 4 to 1 2 inch 6 to 13 mm below the bottom of the filler neck This empty space in the tank allows fuel to expand Never smoke when handling fuel and stay away f...

Page 17: ...mize possible buildup of condensation inside the fuel tank Checking the Engine Oil Level Before you start the engine and use the machine check the oil level in the engine crankcase refer to Checking Oil Level in page Switching the Fuel Tanks Important Do not run the machine out of fuel This may cause engine damage and require the fuel system to be checked The fuel selector valve is located behind ...

Page 18: ...positions See Figure 7 for the positions 3 Install the two pins and secure them with the hairpin cotter pins Figure 8 Figure 7 1 Full down position 2 Down position with bagger installed Important Ensure that the rear part of the seat is secured with the seat latch 4 To raise the roll bar remove the hairpin cotter pins and remove the two pins Figure 8 5 Raise the roll bar to the upright position an...

Page 19: ...d levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure Wear hearing protection when operating this machine Wear protective equipment for your eyes ears feet and head when using this machine Figure 10 1 Warning wear hearing protection Operating the Parking Brake Always set the parking brake when you stop the machine or leave it unattended S...

Page 20: ...t will turn on 8 Release the switch after 10 seconds The light will turn off Figure 12 1 Hour meter 5 Engine Temperature light 2 Ignition switch 6 Throttle control 3 Glow plug switch 7 PTO Switch 4 Glow plug light 9 Turn the key to the start position and the glow plug indicator light will come back on When the engine starts release the key Figure 13 Important Use starting cycles of no more than 30...

Page 21: ...parts to stop before leaving the operating position 5 Remove the key to prevent possibility of someone accidentally starting the machine before transporting or storing machine 6 Close the fuel selector valve before transporting or storing the machine Important Make sure that the fuel selector valve is closed before transporting or storing the machine as fuel leakage may occur Set the parking brake...

Page 22: ... are in the correct position Testing the Safety Interlock System Service Interval Before each use or daily If the safety system does not operate as described below have an Authorized Service Dealer repair the safety system immediately 1 Sitting on the seat engage the parking brake and move the PTO to on Try starting the engine the engine should not crank 2 Sitting on the seat engage the parking br...

Page 23: ...ever toward neutral in the direction you want to turn Figure 17 The farther you move the traction control levers in either direction the faster the machine will move in that direction To stop pull the motion control levers to the neutral position Figure 17 1 Motion control lever neutral lock position 3 Forward 2 Center un lock position 4 Backward Driving Backward 1 Move the levers to the center un...

Page 24: ...e 18 4 Move the lever to the selected height Adjusting the Anti Scalp Rollers Whenever you change the height of cut it is recommended to adjust the height of the anti scalp rollers 1 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 ...

Page 25: ... comfortable To adjust turn the knob in front either direction to provide the best comfort Figure 21 Figure 21 1 Seat suspension knob 2 Seat position lever Changing the Back Position The back of the seat can be adjusted to provide a comfortable ride Position the back of the seat where it is most comfortable To adjust turn the knob under the rightside arm rest in either direction to provide the bes...

Page 26: ...erate machine Figure 24 Note Do not over tighten the by pass valves The machine will not drive unless by pass valves are turned in Figure 24 1 Side console controls 3 Hydraulic pumps 2 By pass valve Transporting Machines Use a heavy duty trailer or truck to transport the machine Ensure that the trailer or truck has all necessary lighting and marking as required by law Please carefully read all the...

Page 27: ...ng down a ramp Both maneuvers can cause the unit to tip backward Loading a unit onto a trailer or truck increases the possibility of backward tip over and could cause serious injury or death Use extreme caution when operating a unit on a ramp Use only a single full width ramp Do Not use individual ramps for each side of the unit If individual ramps must be used use enough ramps to create an unbrok...

Page 28: ...ve onto the stand Stop when the latch drops over the tab into the locked position Figure 27 Once onto the stand engage the parking brake and tun off the engine 7 Chock or block the drive wheels Parking brake may not hold machine parked on Z Stand and could cause personal injury or property damage Do not park on Z Stand unless wheels are chocked or blocked 8 Perform the maintenance Driving off the ...

Page 29: ... frequently If you cannot mow for an extended period first mow at a high cutting height then mow again two days later at a lower height setting Cutting Speed To improve cut quality use a slower ground speed in certain conditions Avoid Cutting Too Low If the cutting width of the mower is wider than the mower you previously used raise the cutting height to ensure that uneven turf is not cut too shor...

Page 30: ...n the water separator Every 50 hours Check the tire pressure Check the PTO drive belt Check the pump drive belt Check the alternator belt Every 100 hours Change the engine oil Check the gear box oil level Check the engine cooling system hoses Inspect the belts for cracks and wear Check the hydraulic hoses Every 150 hours Lubricate the machine with light oil Every 200 hours Change the engine oil fi...

Page 31: ...with a rag Make sure to scrape any paint off the front of the fitting s 4 Connect a grease gun to the fitting Pump grease into the fittings until grease begins to ooze out of the bearings 5 Wipe up any excess grease Greasing the Front Caster Pivots Lubricate the front caster pivots once a year 1 Remove the dust cap and adjust the caster pivots Keep the dust cap off until greasing is done Refer to ...

Page 32: ...of grease weekly 1 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Remove the belt covers 4 Grease the three spindle bearings under the pulleys until grease comes out the lower seals Figure 30 5 Grease the fittings on the push arms...

Page 33: ...ith compressed air 5 Gently slide the filter out of the air cleaner body Figure 32 Avoid knocking the filter into the side of the body 6 Inspect the filter for damage by looking into the filter while shining a bright light on the outside of the filter Holes in the filter will appear as bright spots If the filter is damaged discard it Figure 32 1 Air filter body 3 Air cleaner cover 2 Air filter 4 L...

Page 34: ...Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Clean around the oil dipstick Figure 35 so dirt cannot fall into the filler hole and damage the engine 4 Pull the oil dipstick out and wipe the metal end clean Figure 35 5 Slide the oil dipstick fully into the filler tube Pull the dipstick out and look at the metal end Figure 35 If the oil ...

Page 35: ... the engine Figure 38 This will help the oil to drain 7 Install the drain plug and tighten it to 25 1 2 ft lb 35 N m Note Dispose of the used oil at a recycling center Figure 36 1 Back of machine 2 Drain plug Adding Engine Oil 1 Tilt the seat forward loosen the bolts and remove the front engine panel Figure 37 Figure 37 1 Bolt 2 Front engine panel 2 Remove the oil filler cap and the dipstick Figur...

Page 36: ...ne panel 11 Check for leaks Important Do not overfill the crankcase with oil because this may cause engine damage Changing the Engine Oil Filter Service Interval After the first 50 hours Every 200 hours 1 Drain the oil from the engine refer to Changing the Engine Oil Place a drip pan beneath the oil drip tray to receive oil from the oil filter and oil passages in the engine 2 Turn the filter count...

Page 37: ...he PTO move the motion control levers to the neutral locked position and set the parking brake 3 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 4 Locate the water separator at the back left of the machine 5 Place a drain pan below the water separator 6 Open the drain valve on the water separator approximately one turn to allow water and o...

Page 38: ...l shut off valve Figure 44 5 Loosen the two hose clamps and disconnect the fuel lines from the fuel filter Figure 44 6 Install a new filter Connect the fuel lines to the fuel filter and install the two hose clamps Figure 44 7 Open the fuel shut off valve 8 Start the engine and check for leaks Figure 44 1 Fuel filter 4 Left side of machine 2 Hose clamp 5 Fuel shut off valve 3 Fuel pump Servicing th...

Page 39: ...achine Incorrect battery cable routing could damage the machine and cables causing sparks Sparks can cause the battery gasses to explode resulting in personal injury Always Disconnect the negative black battery cable before disconnecting the positive red cable Always Reconnect the positive red battery cable before reconnecting the negative black cable 1 Disengage the PTO move the motion control le...

Page 40: ...ged 1 265 specific gravity This is especially important to prevent battery damage when the temperature is below 32 F 0 C 1 Make sure the filler caps are installed in battery Charge battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 10 amps 2 When the battery is fully charged unplug the charger from the electrical outlet then disconnect the charger leads from the battery posts Figure 47...

Page 41: ...same distance 2 Check if the machine pulls to one side If it does stop the machine and set the parking brake 3 Unlatch the seat and tilt the seat forward to access the tracking knob Note Determine the left and right sides of the machine from the normal operating position 4 To make the machine go right turn the knob towards the rightside of the machine Refer to Figure 49 5 To make the machine go le...

Page 42: ... 125 ft lb 170 N m Figure 51 Figure 51 1 Slotted Nut 3 Hole in threaded shaft 2 Two threads or less showing 4 Washer if needed 5 Check the distance from bottom of slot in nut to inside edge of hole Two threads or less should be showing Figure 51 6 If more than two threads are showing remove nut and install washer between hub and nut 7 Torque the slotted nut to 125 ft lb 170 N m Figure 51 8 Tighten...

Page 43: ...correct level Figure 53 1 Gear box 3 Rear plug 2 Side plug 4 Pulley Changing the Gear Box Oil Service Interval After the first 100 hours Yearly Contact an Authorized Service Dealer to change the gear box oil Adjusting the Electric Clutch Service Interval Every 500 hours The clutch is adjustable to ensure proper engagement and proper braking 1 Disengage the PTO move the motion control levers to the...

Page 44: ... feeler gauge but it can be moved easily within the air gap Figure 56 11 Repeat this for the remaining slots 12 Check each slot again and make slight adjustments until the feeler gauge between the rotor and armature has very slight contact between them Figure 56 1 Slot 3 Feeler gauge 2 Adjusting nut 13 Install the clutch to the engine shaft with the key 14 Apply blue Loctite or equivalent to the c...

Page 45: ...first 8 hours Every 100 hours Fluid Type 50 50 mix of extended life antifreeze Dex Cool and water Cooling System Capacity 176 ounces 4 6 l Note Do not open the radiator cap Doing this may induce air into the cooling system 1 Position the machine on a level surface stop the engine and set the parking brake 2 Unlatch the seat and tilt the seat up 3 With the engine cool check the overflow bottle leve...

Page 46: ...Figure 59 3 If adjustment is necessary release the parking brake loosen the jam nut below the spring and adjust the nut directly below the spring Figure 59 Turn the nut until the correct measurement is obtained Turn the nut clockwise to shorten spring length and turn counter clockwise to lengthen the spring 4 Tighten the two nuts together 5 Engage the parking brake lever up Check the measurement o...

Page 47: ...relieve belt tension Figure 61 5 Remove the old belt 6 Install the new belt on the pulleys Figure 60 Figure 60 1 Fixed idler arm 4 Mower belt 2 Square hole 5 Belt guide 3 Fixed Idler pulley 6 Spring loaded idler pulley 7 Insert a ratchet with a short extension or a breaker bar into the square hole in the fixed idler arm Figure 61 8 Adjust the mower deck to the 3 inch 76mm height of cut position 9 ...

Page 48: ...et the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Tilt the seat forward loosen the bolts and remove the front engine panel Figure 63 Figure 63 1 Knob 2 Front engine panel 4 Remove the spring from the idler arm Figure 64 5 Remove the clutch stop bracket 6 Remove the old PTO drive belt 7 Install the PTO drive belt arou...

Page 49: ...op the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Remove the 4 bolts holding the oil cooler shield to the rear frame Figure 66 4 Remove the 3 bolts holding the engine straps to the side of the machine Figure 66 Figure 66 1 Oil cooler shield 3 Engine straps 2 Bolts 5 Remove the 4 bolts holding the oil cooler and position the oil cooler to the...

Page 50: ...Neutral Position If motion control levers do not align or move easily into the console notch adjustment is required Adjust each lever spring and rod separately Note Motion control levers must be installed correctly See Installing the Motion Control Levers in the set up instructions 1 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop th...

Page 51: ...l Important Use oil specified or equivalent Other fluids could cause system damage Note There are two ways of checking the hydraulic oil One is when the oil is warm and one is when the oil is cold The baffle inside the tank has two levels depending if the oil is warm or cold 1 Position the machine on a level surface and set the parking brake 2 Clean the area around filler neck of hydraulic tank Fi...

Page 52: ...ve 32 F 0 C Use winter filter below 32 F 0 C 1 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position Important Do not substitute automotive oil filter or severe hydraulic system damage may result 3 Place drain pan under filter remove the o...

Page 53: ...osite wheel Checking the Hydraulic Hoses Service Interval Every 100 hours Check the hydraulic hoses for leaks loose fittings kinked lines loose mounting supports wear weather and chemical deterioration Make necessary repairs before operating Note Keep areas around the hydraulic system clean from grass and debris build up Hydraulic fluid escaping under pressure can penetrate skin and cause injury I...

Page 54: ... motion control lever forward and reverse then back to neutral The wheel must stop turning or slightly creep in reverse 4 Open the throttle to fast Make sure wheel remains stopped or slightly creeps in reverse adjust if necessary Figure 75 1 Tracking knob 4 Turn this way to track right 2 Hydraulic tank 5 Turn this way to track left 3 Hydraulic pumps Setting the Left hand Hydraulic Pump Neutral Pos...

Page 55: ... parking brake 3 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 4 Check tire pressure of all four tires If needed adjust to 13 psi 90 kPa 5 Lower the mower to the 3 inch 76 mm height of cut position 6 Inspect the four chains The chains need to have tension If one rear chain is loose lower loosen the front support arm on the same side Refe...

Page 56: ...ocation from a level surface to the cutting edge of the blade tip Figure 79 Figure 79 1 Measure here from blade to hard surface 2 Measure at A and B 3 Record this measurement 4 Measure the right blade at the B location from a level surface to the cutting edge of the blade tip Figure 79 5 Record this measurement 6 The mower blade should be a 1 4 to 3 8 inch 6 to 10 mm lower at position A than at po...

Page 57: ...orn replace it immediately with a genuine Toro replacement blade For convenient sharpening and replacement you may want to keep extra blades on hand A worn or damaged blade can break and a piece of the blade could be thrown into the operator s or bystander s area resulting in serious personal injury or death Inspect the blade periodically for wear or damage Replace a worn or damaged blade Inspect ...

Page 58: ...solid object is hit if the blade is out of balance or is bent To ensure optimum performance and continued safety conformance of the machine use genuine TORO replacement blades Replacement blades made by other manufacturers may result in non conformance with safety standards Contact with a sharp blade can cause serious injury Wear gloves or wrap sharp edges of the blade with a rag 1 Hold the blade ...

Page 59: ...5 1 Sail Area of Blade 4 Blade Bolt 2 Blade 5 Cone Towards Bolt Head 3 Spring Disk Cleaning Cleaning Under the Mower Remove the grass buildup under the mower daily 1 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Raise the mower t...

Page 60: ... Run the machine with the PTO engaged and the engine at high idle for 2 to 5 minutes after washing 11 Check the condition of the blades refer to Servicing the Cutting Blades in page 12 Prepare the machine for storage when non use occurs over 30 days Prepare the machine for storage as follows A Add a petroleum based stabilizer conditioner to fuel in the tank Follow mixing instructions from the stab...

Page 61: ...lter The engine loses power 7 Dirt water or stale fuel is in the fuel system 7 Contact an Authorized Service Dealer 1 The engine load is excessive 1 Reduce the ground speed 2 The oil level in the crankcase is low 2 Add oil to the crankcase 3 The cooling fins and air passages above the engine are plugged 3 Remove the obstruction from the cooling fins and air passages 4 The coolant level in radiator...

Page 62: ... broken 1 Check the belt tension 2 The PTO drive belt is off pulley 2 Install the drive belt and check adjusting shafts and belt guides for correct position 3 The mower deck belt is worn loose or broken 3 Install a new mower deck belt 4 The mower deck belt came off a pulley 4 Install mower deck belt and check the idler pulley idler arm and spring for the correct position and function 5 The pump dr...

Page 63: ...Schematics Wire Diagram Rev A 63 ...

Page 64: ...Notes 64 ...

Page 65: ...Notes 65 ...

Page 66: ...Notes 66 ...

Page 67: ...gypt 202 519 4308 Ibea S p A Italy 39 0331 853611 Irriamc Portugal 351 21 238 8260 Irrigation Products Int l Pvt Ltd India 86 22 83960789 Jean Heybroek b v Netherlands 31 30 639 4611 Lely U K Limited United Kingdom 44 1480 226 800 Maquiver S A Colombia 57 1 236 4079 Maruyama Mfg Co Inc Japan 81 3 3252 2285 Metra Kft Hungary 36 1 326 3880 Mountfield a s Czech Republic 420 255 704 220 Munditol S A A...

Page 68: ...tact your seller you may contact any Toro Authorized distributor to arrange service 2 Bring the product and your proof of purchase sales receipt to your seller of the Service Dealer 3 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact the Toro importer or dontact us at LCB Customer Service Department Toro Warranty Company 8111 Lyndale ...

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